Brake Pedal Interface Cage With Controlled Pushrod Breakthrough

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Solution Overview

Problem

Existing brake pedal systems in vehicles do not adequately protect the driver's foot and leg from injury during a crash, as they fail to allow sufficient forward movement of the pedal arm and foot pad under high forces, leading to increased pressure on the driver's foot and leg.

Innovation Solution

A brake booster pushrod to pedal interface cage with weakened portions, such as slits or openings, allows the pushrod to move through the cage at a predetermined force, enabling further forward movement of the pedal arm and foot pad, reducing the force exerted on the driver's foot and leg during a crash.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the brake pedal system uses a rigid interface cage to secure the pushrod, then the structural strength and reliability are improved, but the forward movement capability under high force is reduced, causing increased pressure on the driver's foot and leg during a crash

Engineering Contradiction:

Improvestructural strengthVSAvoidpressure on driver's foot and leg

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The interface cage is segmented with weakened portions (slits or openings) that divide the rigid structure into sections. These segmented weak portions allow the pushrod to push through the cage during high-force crash events, enabling additional forward movement of the pedal arm and foot pad to reduce pressure on the driver's foot and leg.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interface cage's structural parameter is changed by introducing weakened portions with reduced material thickness or cross-section. This creates a controlled weakness that allows the cage to deform or be pushed through at predetermined forces, transforming the rigid structure into one that can yield under extreme conditions to reduce harmful pressure on the driver.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the interface cage is made rigid to hold the pushrod securely, then the reliability of the brake system is improved, but the ability to allow further forward movement during a crash is reduced

Engineering Contradiction:

Improvereliability of brake systemVSAvoidforward movement distance

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The interface cage is divided into strong portions that maintain secure holding of the pushrod during normal operation and weak portions (slits or openings) that allow pushrod penetration during crashes. This segmentation enables the structure to provide reliability when needed while allowing movement under extreme forces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The weakened portions are designed in advance to fail at predetermined forces, creating a safety mechanism that activates only during crash conditions. This beforehand design allows the system to maintain reliability during normal use while pre-preparing a failure mode that enables additional forward movement to reduce driver injury.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Stability of the object's composition

If the interface cage structure is strengthened to prevent pushrod movement, then the structural stability is improved, but the ability to reduce driver injury through increased pedal travel is reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidcrash forces on driver

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The interface cage has non-uniform local quality with strong portions for structural stability and weak portions (slits or openings) for controlled failure. The strong portions maintain stability during normal operation, while the weak portions located strategically allow pushrod penetration during crashes to reduce harmful forces on the driver's foot and leg.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The local parameter of material thickness or cross-sectional area is changed at specific locations to create weakened portions. These parameter changes create zones of controlled weakness that allow the pushrod to push through the cage at predetermined forces, enabling additional pedal travel to reduce crash forces on the driver while maintaining overall structural stability.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4574589A1Brake pedal with safety features

Publication Date: 2025.06.25 VOLVO CAR CORP

Figure 1A~1B
Figure 2A~2B
Figure 2C~2D

AI summary

A brake booster pushrod to pedal interface cage comprises a plurality of side walls; a front face connecting to each of the plurality of side walls at or near a first side of the plurality of side walls, the front face comprising a recess for receiving an end of a booster pushrod; and at least one weakened portion configured to allow the booster pushrod to move through the front face at a predetermined force.